U.S. patent application number 17/747508 was filed with the patent office on 2022-09-01 for foam panel with drainage plane.
This patent application is currently assigned to Ox Engineered Products, LLC. The applicant listed for this patent is Ox Engineered Products, LLC. Invention is credited to Sarah Overman.
Application Number | 20220275643 17/747508 |
Document ID | / |
Family ID | 1000006378601 |
Filed Date | 2022-09-01 |
United States Patent
Application |
20220275643 |
Kind Code |
A1 |
Overman; Sarah |
September 1, 2022 |
FOAM PANEL WITH DRAINAGE PLANE
Abstract
A method of forming a building panel includes embossing dimples
into a sheet, where the dimples extend outward from a plane, and
expanding a foam core onto the plane and into portions of the
dimples. The method may include forming dimples that are convex
relative to the plane and the foam core or the sheet having a thin
foil having a plastic protective coating. The method may include
attaching a cellulosic layer to the foam core opposite the plane.
Additionally, flow channels may be formed in the sheet between the
dimples, such that expanding the foam core onto the plane
substantially fills both the dimples and the flow channels. The
method may include embossing concave dimples onto the plane and the
foam core, such that expanding the foam core onto the plane
substantially fills the concave dimples. The foam core and sheet
may bond without adhesives.
Inventors: |
Overman; Sarah; (Berkley,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ox Engineered Products, LLC |
Northville |
MI |
US |
|
|
Assignee: |
Ox Engineered Products, LLC
Northville
MI
|
Family ID: |
1000006378601 |
Appl. No.: |
17/747508 |
Filed: |
May 18, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62906998 |
Sep 27, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04C 2/205 20130101;
E04C 2002/3411 20130101 |
International
Class: |
E04C 2/20 20060101
E04C002/20 |
Claims
1. A method of forming a building panel, comprising: embossing
dimples into a sheet, such that the dimples extend outward from a
plane; and expanding a foam core onto the plane and into portions
of the dimples, to thereby form the building panel.
2. The method of claim 1, wherein the dimples are convex relative
to the plane and the foam core.
3. The method of claim 2, wherein the sheet is a thin foil having a
plastic protective coating.
4. The method of claim 3, further comprising: attaching a
cellulosic layer to the foam core opposite the plane and the
dimples.
5. The method of claim 4, wherein a plurality of flow channels are
formed in the sheet between the dimples, and wherein expanding the
foam core onto the plane substantially fills the dimples and the
flow channels.
6. The method of claim 1, wherein a plurality of flow channels are
formed in the sheet between the dimples, and wherein expanding the
foam core onto the plane substantially fills the dimples and the
flow channels.
7. The method of claim 2, wherein a plurality of flow channels are
formed in the sheet between the dimples, and wherein expanding the
foam core onto the plane substantially fills both the dimples and
the flow channels.
8. The method of claim 7, further comprising: embossing dimples
that are concave relative to the plane and the foam core, wherein
expanding the foam core onto the plane substantially fills the
convex dimples, the concave dimples, and the flow channels.
9. The method of claim 1, wherein expanding the foam core onto the
sheet bonds the foam core to the sheet without additional
adhesives.
10. The method of claim 1, wherein the sheet is a thin foil having
a plastic protective coating.
11. The method of claim 1, further comprising: attaching a
cellulosic layer to the foam core opposite the plane and the
dimples.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. Non-Provisional
patent application Ser. No. 17/028,541, filed 22 Sep. 2020, which
claimed priority from U.S. Provisional Patent Application No.
62/906,998, filed 27 Sep. 2019, both of which are hereby
incorporated by reference in their entirety.
INTRODUCTION
[0002] This disclosure generally relates to foam insulating panels
or sheathing panels, such as those used on building walls or
roofs.
SUMMARY
[0003] A method of forming a building panel is provided. The method
includes embossing dimples into a sheet, such that the dimples
extend outward from a plane, and expanding a foam core onto the
plane and into portions of the dimples. The method may include
forming dimples that are convex relative to the plane and the foam
core, and the sheet having a thin foil having a plastic protective
coating.
[0004] The method may include attaching a cellulosic layer to the
foam core opposite the plane and the dimples. Additionally, a
plurality of flow channels may be formed in the sheet between the
dimples, such that expanding the foam core onto the plane
substantially fills both the dimples and the flow channels.
[0005] The method may include embossing dimples that are concave
relative to the plane and the foam core, such that expanding the
foam core onto the plane substantially fills the convex dimples,
the concave dimples, and the flow channels. Expanding the foam core
onto the sheet may bond the foam core to the sheet without
additional adhesives or other attachment mechanisms.
[0006] The above features and advantages, and other features and
advantages, of the present disclosure are readily apparent from the
following detailed description of some of the best modes and other
embodiments for carrying out the disclosure, which is defined
solely by the appended claims, when taken in connection with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic, plan view of a building assembly with
a plurality of foam panels assembled to a wall of a building.
[0008] FIG. 2 is a schematic, exploded view of an illustrative
portion of a foam panel usable with building assemblies.
[0009] FIG. 3 is a schematic, side view of a portion of a foam
panel having hexagonal dimples and usable with building assemblies,
such as that shown in FIG. 1, showing that the foam fills the
dimples.
[0010] FIG. 4 is a schematic, front view of another portion of a
foam panel having hexagonal dimples and usable with building
assemblies.
[0011] FIG. 5A is a schematic, front view of another portion of a
foam panel having round dimples with flow channels formed
therebetween usable with building assemblies.
[0012] FIG. 5B is a schematic, side view of a portion of a foam
panel having round or spherical outward dimples usable with
building assemblies showing that the foam fills the dimples and the
flow channels.
[0013] FIG. 5C is a schematic, side view of a portion of a foam
panel having a plurality of round or spherical outward first
dimples and a plurality of inward second dimples usable with
building assemblies showing that the foam fills the dimples and the
flow channels.
[0014] FIG. 6 is a schematic, front view of another portion of a
foam panel having spaced, round dimples usable with building
assemblies.
DETAILED DESCRIPTION
[0015] Referring to the drawings, like reference numbers correspond
to like or similar components wherever possible throughout the
several figures. FIG. 1 shows an illustrative portion of a building
assembly 10 at least partially installed on a wall 12 of a building
(not fully shown). Reference to the figures and the general
description is exemplary of the following features, embodiments, or
configurations, in addition to other features, embodiments, or
configurations recognizable to skilled artisans.
[0016] A plurality of panels 14, are assembled to the wall 12. The
panels 14 may also be referred to as foam panels 14, sheathing
panels 14, building panels 14, or housing panels 14, depending on
the configuration used in the building assembly 10 or the language
used by skilled artisans. In the configuration shown in FIG. 1, the
panels 14 are butted against one another and several of the joints
are covered with joint tape 16, such as flashing tape or seam tape,
which generally creates a waterproof assembly over the wall 12,
when properly installed, as recognized by skilled artisans. Some
configurations may not require the joint tape 16.
[0017] The panels 14 may be formed in 4-foot by 8-foot rectangles,
other common sizes, or custom formed to fit specific applications,
such as covering the entire wall 12 with a single panel 14. In many
configurations, the panels 14 will be configurated, as recognized
by skilled artisans, to provide shear bracing, continuous
insulation, transverse wind resistance, and an air and
water-resistive barrier.
[0018] The panels 14 may be attached to the wall 12 via fasteners
(not shown) driven into a plurality of framing members 18, which
may be formed from wooden, metal, or other suitable framing
materials. The wall 12 may also be formed from concrete or masonry,
with the panels 14 appropriately attached thereto, as would be
recognized by skilled artisans.
[0019] While the building assembly 10 may be illustrated and
discussed relative to vertical, or substantially vertical, exterior
walls 12, it may also be applied to sloped walls or roof
structures. Additionally, the building assembly 10 may be installed
on interior, or partially exterior, walls, and may be used above or
below grade.
[0020] In practice, the panels 14 may be covered by a plurality of
siding or cladding elements that provide aesthetic and functional
finishing of the building. The siding elements interacting with the
building assembly 10 may be numerous types of siding or roofing
products. The siding elements may include, without limitation:
natural wooden shakes or shingles; natural, artificial, or
composite plank or lap siding; metal siding; wooden, slate, or
asphalt shingles; stone or brick veneer; or fibrous cement
panels.
[0021] While the present disclosure may be illustrated with respect
to particular industries or applications, those skilled in the art
will recognize the broader applicability of the products and
methods described herein. For example, similar structures, methods,
or combinations thereof, may be used in other industries,
including, without limitation: residential, commercial, or
industrial structures.
[0022] Those having ordinary skill in the art will also recognize
that terms such as "above," "below," "upward," "downward," et
cetera, are used descriptively of the figures, and do not represent
limitations on the scope of the appended claims. Any numerical
designations, such as "first" or "second" are illustrative only and
are not intended to limit the scope of the claims in any way.
[0023] When used herein, the term "substantially" refers to
relationships that are ideally perfect or complete, but where
manufacturing realties prevent absolute perfection. Therefore,
substantially denotes typical variance from perfection. For
example, if height A is substantially equal to height B, it may be
preferred that the two heights are 100.0% equivalent, but
manufacturing realities likely result in the distances varying from
such perfection. Skilled artisans would recognize the amount of
acceptable variance. For example, and without limitation,
coverages, areas, or distances may generally be within 10% of
perfection for substantial equivalence. Similarly, relative
alignments, such as parallel or perpendicular, may generally be
considered to be within 5%.
[0024] Features shown in one figure may be combined with,
substituted for, or modified by, features shown in any of the
figures. Unless stated otherwise, no features, elements, or
limitations are mutually exclusive of any other features, elements,
or limitations. Any specific configurations shown in the figures
are illustrative only and the specific configurations shown are not
limiting.
[0025] Referring also to FIGS. 2, 3, and 4, and with continued
reference to FIG. 1, there are shown additional views of example
panels 14. FIG. 2 shows a schematic, exploded view of a portion of
one of the panels 14; FIG. 3 shows a schematic, side view of a
portion of one of the panels 14; and FIG. 4 shows a schematic,
front view of a portion of one of the panels 14. The components
shown in FIGS. 2-4 may be different embodiments of panels 14 shown
in FIG. 1, and may also be illustrating alternative features.
[0026] As shown in the figures, the panels 14 may be formed from a
plurality of layers. The views shown in the figures are
illustrative only, and additional, or fewer, layers may be used to
form the panels 14.
[0027] A foam core 20 is located between a cellulosic layer 22 and
a drainage plane 24 on the opposite side of the foam core 20 from
the cellulosic layer 22. The cellulosic layer 22 may improve the
structural strength and resistance to shear of the wall 12.
However, many configurations of the panels 14 may not include the
cellulosic layer 22, such that the panel 14 is formed from the foam
core 20 and the drainage plane 24--possibly with additional layers
or features.
[0028] The foam core 20 acts as insulation and adds a thermal
barrier to the building assembly 10. The foam core 20 may also
provide structural benefits. The foam core 20 may be formed from a
closed-cell, moisture-resistant, polyisocyanurate (polyiso) foam.
The foam core 20 provides high compressive strength, a long-term
R-value, and a continuous air barrier.
[0029] The foam core 20 may be formed by expanding foam between the
cellulosic layer 22 (or any other layers included in the panels
14). In configurations that do not include the cellulosic layer 22,
the foam core 20 may be expanded between a die plate and the
drainage plane 24, or between an additional film or facer layer and
the drainage plane 24. In alternative configurations, the foam core
20 may be preformed to any of its available thicknesses, and then
have the cellulosic layer 22, the drainage plane 24, or both,
attached or adhered thereto.
[0030] The cellulosic layer 22 may be formed from pressure
laminated plies having high-strength cellulosic fibers.
Furthermore, the fibers and the binder incorporated into the
cellulosic layer 22 may be specially treated to be water resistant
and may be bonded with a water-resistant adhesive. Therefore, the
binder and the fibers may form an air and water-resistive barrier
(WRB) within the cellulosic layer 22 and the drainage plane 24.
[0031] The panel 14 may also include one or more barrier layers or
facers, which further limit passage of air and water vapor through
the panel 14. The air and water-resistive barriers may be located
in different, and multiple, portions of the panel 14. In FIG. 2,
there is a barrier layer 32 illustrated as part of the cellulosic
layer 22. The barrier layer 32 limits or minimizes passage of air,
water, and water vapor through panels 14, and may be located in
different portions of the panels 14. Furthermore, additional
barrier layers may be incorporated into other portions of the
panels 14.
[0032] In some configurations, the barrier layer 32 may be a facing
adhered to one or more sides of the foam core 20. When the barrier
layer 32 forms part of the foam core 20, the air and
water-resistive capabilities of the foam core 20 are enhanced over
the foam alone. The foam material, itself, may also limit passage
of air and water through the panels 14.
[0033] As shown in FIGS. 2-4, the drainage plane 24 is attached to
one side of the foam core 20, generally the exterior or outward
side, relative to the building interior. The drainage plane 24 may
be formed from a film made with foil, plastic, or combinations
thereof. For example, and without limitation, the drainage plane 24
may be formed from a thin foil (possibly a reflective foil) with a
clear protective coating. Alternatively, the drainage plane 24 may
have several layers, including, without limitation: coated foil
layers, paper or paper-like layers, PET (Polyethylene
terephthalate) layers, or various combinations thereof. The
drainage plane 24 may also be referred to as a facer or facer layer
and is likely to be formed from, for example, and without
limitation, either foil or foil plus PET. Note that either, or
both, sides of the panels 14 may be printed or painted with logos,
technical specifications, or installation instructions.
[0034] The drainage plane 24 may be embossed or otherwise shaped to
create a three-dimensional profile, as shown in the figures. A
plurality of dimples 34 are formed in the drainage plane 24 and
extend outward from the foam core 20. A plurality of flow channels
36 are thereby formed between the dimples 34 and are recessed
relative to the outwardly extended dimples 34. The dimples 34, and
other examples, shown in the figures, are illustrative only. Note
that the drainage channels or flow channels 36 are formed by the
areas of the drainage plane 24 that do not include the dimples
34.
[0035] As illustrated in FIG. 3, the panels 14 may have a cladding
layer or cladding 40 attached to the outside. The cladding 40
generally completes the building assembly 10 by adding an aesthetic
and/or functional finishing layer--although the cladding 40 may
also be painted or otherwise treated--and may incorporate the
previously discussed siding elements. That the cladding 40 shown is
illustrative only, and may be numerous shapes and sizes and
configurations, including those listed above and others, as will be
recognized by skilled artisans.
[0036] In many configurations of sheathing or foam panels, there
would need to be either spacing members or a separate building wrap
placed between the cladding 40 and the sheathing or foam panels.
However, the panels 14 may have the cladding 40 pressed directly
against the dimples 34 of the drainage plane 24.
[0037] The dimples 34 provide separation between the cladding 40
and portions of the drainage plane 24, particularly the flow
channels 36. Therefore, water or moisture that finds its way
between the cladding 40 and the drainage plane 24 is able to flow
downward (relative to gravity and to the view of FIGS. 2-4) through
the flow channels 36. Flashing or other elements (not shown) may
assist in removing drained water from the panels 14, or the water
may simply fall downward after leaving the panels 14. Importantly,
any water between the foam core 20 and the cladding 40 is able to
move downward, as opposed to staying within the panel 14 or moving
into the building, and is able to do so without the addition of
dedicated spacer elements or additional wrap layers.
[0038] The drainage plane 24 may be formed by embossing the dimples
34 into a sheet of foil film, or other suitable materials.
Depending on the configuration, the flow channels 36 may be
positively formed or may be the un-embossed portion of the original
sheet material.
[0039] As viewed in FIG. 4, the flow channels 36 of the drainage
plane 24 define both vertical and horizontal moisture pathways,
relative to gravity. This provides two directions of flow, and
differentiates from an alternative system that has only vertical
channels or vertical grooves, such as vertical firing strips
located between the foam and the cladding. In the configuration
shown in FIGS. 3 and 4, the dimples are formed in a honeycomb or
hexagonal shape. Therefore, the horizontal pathways provided by the
flow channels 36 are angled between 30-60 degrees relative to the
vertical pathways, such that they still promote downward flow of
water. The staggered configuration of the dimples 34 also
differentiates over vertical features, and allows more support
between elements than vertical firing strips and the like.
[0040] Note that the tightly spaced pattern of the dimples 34 is
illustrative only. Some configurations may have fewer dimples 34
and/or widely spaced dimples 34. In configurations with fewer
dimples 34, the flow channels 36 may be partially formed by flat
areas between the dimples 34, which may form a substantially planar
structure between the dimples 34.
[0041] As viewed in FIG. 3, the foam core 20 extends into a convex
surface 35 defined by each of the plurality of dimples 34, such
that the back sides of the dimples 34 are substantially filled by
the foam material. This configuration may be achieved by either
forming the foam with the same dimple shapes as the drainage plane
24, or by using rising or expanding foam that expands into convex
surfaces 35 of the dimples 34 during formation of the panels
14.
[0042] The foam-filled dimples 34 may further enhance the strength
of the drainage plane 24 against the pressure of the cladding 40 or
other exterior attachments, such that the dimples 34 are less
likely to be compressed or collapsed and the flow channels 36 more
likely to remain open. Additionally, because the free rise foam
bonds to the convex surfaces 35 on the back side of the dimples 34,
the drainage plane 24 may be attached to the foam core 20 without
added glue, adhesives, or fasteners because the free rise foam
bonds or adheres itself directly to the drainage plane 24. Direct
bonding of the free rise foam core 20 allows the panels 14 to be
assembled with fewer processes and with fewer components.
[0043] Note that the free rising foam may not completely, or
entirely, fill the convex surfaces 35 of the dimples 34. However,
the foam coverage within the dimples 34 would be substantially
filling the dimples 34 if it is sufficient to both bond the
drainage plane 24 to the foam core 20 and to support the dimples 34
against the pressure of the cladding 40.
[0044] In FIG. 1, the panels 14 are butted against one another and
covered with joint tape 16 to create a waterproof assembly over the
wall 12. To limit incursion of water or moisture into the building,
the seams between the panels 14 will likely be sealed in some
fashion. In addition to the joint tape 16, other options may
include, without limitation, caulking, adhesives, or injectable
sealants.
[0045] In other configurations, the panels 14 may be installed with
a slight overlap, in lieu of the joint tape 16, to form the
waterproof assembly. In some configurations, the drainage plane 24,
for example, may extend somewhat beyond the foam core 20 on one or
two edges of the panels 14. In such configurations, the foam cores
20 of adjacent panels 14 may abut one another, but the drainage
plane 24 of one panel 14 would overlap the drainage plane 24 of the
adjacent panel 14, creating a lapped installation that may minimize
water intrusion.
[0046] In other configurations, the panels 14 may have edge
portions of the drainage plane 24 that are formed without the
dimples 34, or with widely spread dimples 34. With flat edges or
fewer dimples 34 on the edges, it may be easier to apply the joint
tape 16 to seal the seams between the panels 14. Additionally,
flashing elements may be used at the seams between the panels 14 to
seal the building assembly 10.
[0047] In some configurations, the panel 14 may further include a
reflective layer (not separately shown). The reflective layer may
be a single or double-sided reflective foil surface, or a
multi-layer surface partially formed from foil or other reflective
materials, and may be located on different portions of the panel
14. In some configurations, the reflective layer may be attached to
the foam core 20 opposite the drainage plane 24, such as between
the cellulosic layer 22 and the foam core 20 or in lieu of the
cellulosic layer 22. Furthermore, the reflective capabilities may
be part of the foil film layer incorporated into the drainage plane
24, such that the drainage plane 24 has reflective
characteristics.
[0048] In most configurations of the panels 14, such as that
schematically illustrated in the figures, the cellulosic layer 22
will be placed toward the interior of the building, with the
drainage plane 24 facing the exterior. However, other
configurations may be used, such as with the drainage plane 24
toward the interior of the building.
[0049] The preformed panels 14 may be attached to the wall 12 with
various fasteners, as would be recognized by those having ordinary
skill in the art. For example, and without limitation: nails or
staples may be used to attach the panels 14 to wooden framing
members 18, and self-drilling screws may be used to attach to metal
framing members 18.
[0050] Note that various fasteners may be used to attach the
cladding 40 to the panels 14 and the wall 12, as would be
recognized by skilled artisans. Additionally, the foam core 20, the
cellulosic layer 22, and the drainage plane 24 of the panels 14 may
provide enhanced sealing between the fasteners and the panels 14,
relative to standard applications, such that neither gaskets nor
sealants are required at the interface of the panels 14 and any of
the fasteners.
[0051] Note that most applications of the panels 14 do not require
additional layers, such as house or building wraps, for air and
water resistance. The foam core 20 of the panels 14 may provide
enhanced sealing around the fasteners used to attach the panels 14
to the wall 12, which further improves the insulating capabilities
of the building assembly 10.
[0052] The configurations and/or embodiments shown in the figures
may not be shown to scale. The panels 14 may be formed with
different layer configurations, and, also, formed with different
thicknesses of the components. The examples given below, as well as
those shown in the figures, are illustrative of only a few possible
configurations. For example, and without limitation, the foam core
20 may range in thickness from 0.50 inches to 4.0 inches.
Furthermore, the R-values of the foam core 20, alone, may range
from 3.0 to 25.0 or more.
[0053] The thickness of the cellulosic layer 22, when included in
the panel 14, may range from, for example, and without limitation,
0.078-0.135 inches. Note that manufacturing variability may result
in thicknesses outside of the ideal sizes. The resulting, combined,
R-values of the panels 14 may be greater than that of the foam core
20 alone. Furthermore, because the cellulosic layer 22 and the
drainage plane 24 add air and water barriers, the effective
insulating value of the panel 14 may be increased.
[0054] Referring also to FIGS. 5A, 5B, and 5C, and with continued
reference to FIGS. 1-4, there are shown additional views of
exemplary foam panels. FIG. 5A is a schematic, front view of a
portion of another foam panel, or simply panel 114, having a
drainage plane 124 with a plurality of round dimples 134. FIG. 5B
is a schematic, side view of a portion of the panel 114, showing
the round or spherical dimples 134 extending outward. FIG. 5C is a
schematic, side view of a portion of the foam panel 114, but
configured with both first outward dimples 134 and second inward
dimples 135. Each of the illustrated panels 114 may be used with
building assemblies, such as that shown in FIG. 1.
[0055] The drainage planes 124 shown in the figures are attached to
a foam core 120, which may be formed from free rising foam that
extends into convexities on the back side of the outward dimples
134, which are convex to the foam core 120. A plurality of flow
channels 136 are formed between the dimples 134.
[0056] The panels 114 may also be formed by embossing the drainage
plane 124 after it is attached, as a flat sheet or film, to the
foam core 120. Therefore, the dimples 134 and the flow channels 136
may be formed substantially simultaneously in both the drainage
plane 124 and the foam core 120.
[0057] In the configuration shown, the panels 114 have both
vertical and horizontal flow paths. A cladding layer or cladding
140 may be attached to the panels 114. The flow channels 136 are
offset from the cladding 140 by the dimples 134 of the drainage
plane 124. Therefore, water between the cladding 140 and the panels
114 can flow downward (relative to gravity) and is not trapped
between the components.
[0058] Although several of the examples illustrated herein have
outward dimples--i.e., extending away from the foam--the
configuration of FIG. 5C also has inward, or second, dimples 135.
In the configuration of FIG. 5C, the inward dimples 135 may provide
further spacing between the foam core 120 and the cladding 140.
[0059] The inward dimples 135 are concave relative to the foam core
120. The outward dimples 134 will space to cladding 140, such that
any water that moves between the foam core 120 and the cladding 140
will flow downward via the flow channels 136 and also the inward
dimples 135 and be removed from the panels 114.
[0060] Although only rounded dimples 134 and hexagonal dimples 34
are illustrated herein, additional shapes and configurations may be
used with the panels. For example, and without limitation, drainage
planes 124 with differently sized dimples, differently spaced
dimples, as well as different shapes of dimples may be used on the
same plane.
[0061] Referring also to FIG. 6, and with continued reference to
FIGS. 1-5C, there is shown an additional view of a portion of a
panel 214 having of a drainage plane 224 with a plurality of round
dimples 234. The dimples 234 shown in FIG. 6 have greater spacing
than those of the other drainage planes shown in the figures. A
plane of flow channels 236 is formed between the dimples 234.
[0062] For example, and without limitation, the pattern of the
dimples 234 may be spaced between 0.5-0.75 inches, center to
center. The diameter may be, for example, between 0.2-0.30 inches
and the dimples 234 may be offset convexly from the plane by
0.015-0.030 inches. The depth of the embossed elements--dimple
shaped elements on, for example, rollers--may be greater than the
resulting dimple depth, in order to account for return or spring
back of the material forming the drainage plane 224. The foam core
(not viewable in FIG. 6) would extend into the back side of the
convex dimples 234. The dimples 234 may be offset from row to row
by, for example, between 0.30-0.40 inches. In some configurations,
depending on the cladding (not shown) and fasteners (not shown)
used, some portions of the plane of the flow channels 236 may
contact the cladding. However, moisture would still be able to flow
through other areas of the flow channels 236.
[0063] Methods of making panels similar to those described herein
may include embossing a sheet of thin foil having a plastic
protective coating and forming dimples in the sheet via the
embossing. Depending on the material forming the drainage plane,
the embossing elements may result in the final shape of the dimples
or there may be some return or give--such that foil plus PET
drainage planes are likely to have dimples with lesser depth than
drainage planes formed from foil alone. Then, the formed drainage
plane may have free rise foam expanded onto it, such that the
convex portions of the dimples are (at least partially) filled. In
many situations, the free rise foam will substantially fill the
dimples (whether convex or concave) and the drainage channels
therebetween. Additional layers, such as cellulosic layers, other
protective coatings, or reflective foils may then be applied, in
addition to printing branding and/or instructions onto the
panels.
[0064] The detailed description and the drawings or figures are
supportive and descriptive of the disclosure. While some of the
best modes and other embodiments for carrying out the disclosure
have been described in detail, various alternative designs,
configurations, and embodiments exist for practicing the appended
claims.
* * * * *